Control system



March 3, 1931. v O NEEDHAM 1,794,977

CONTROL SYSTEM Filed Nov. 23, 1927 3 INVENTOR O/fle A/e o/? 62/77.

3/ 32 as ATTbRNEY Patented-Friar. 3, 1931 V *wnrso rams ra ser v OLLIE NEEnHArr, or WI KInsBnR'e, PENNSYLVANIA nssrenon To wnsrrnenonsn ELECTRIC & MANUFACTURING COMPANY, eenronerron or rnnnsynvanrn CONTROL srs'rmvr.

Application file i November 23, 1927. Serial No. 235,229.

This invention relates to motor control sys tems and more particularly to control sys- "tems for synchronous motors suitable to be utilized for operating similar machines. 4 v v Inthe operation of rolling mills, and espeeially bloomingmills, it is desirable to provide a driving motorcapablejofoperating for short intervals under heavy overl-oads'such as to occur when starting rollingoperations. The

usual practice is to either employ 'a synchronous motor direct-connected to the rolls of themil-l, or to provide an adjustable speed direct-current motor to drive the rolls and utilize a synchronous motor-generator set for supplying power to the direct-current driving motor. To insure that the mill Will be kept in continuous operation regardless of the ove'rloading which may occur quitefrequent Z0 1y, although existing only momentarily,- a synchronous motor having sutiicient pull-out or maximum torque must be provided. It is well known in the art that the pull-out oi maximum torque of a synchronous motor an be materially increased by over-exeiting the field. However, continuous over-cxcitation of the hold is undesirable as it will result in over-heatingand, consequently, burning "011:? of the field win-ding. Furthermore, it

so is well known that over-exeitationof' a synchronous motor causes the'motor to draw an excessive amount of leading currentfrom the line which may -b8' 0b]i3101121bl 1n many' I T he taking of a leading current alters the power-factor of the power system andusually results in theimposition of penalties on themill owneix' 'Therefore, it wlll 1 be readily understood that In order to provide the'rcquired amount of maximum torqueto 49 keep the mall in operation during the high peak load periods, a motor'must be provlde'd j vhic i has a higher rating than that required for the normal mlll load and results in a high installation cost. 7

conditions provisionis made for varying its field strength by a power relay" 1n such a 50 manner as to'provide for over-excitation of rolling mills and In thisinvention, a synchronous motor-0t adequate rating for thenormal load of the mill is utilized and in order to meet overload the field Whenever a peak load occurs, the excitation at all other times being controlled in the usualimanner bya field rheostat so that the motor will not alter the power factor of the line excessively. Intermittent high values of exciting current although greatly in excess of the rated capacity of the field wind- 'ing it-only momentary will not cause damage.

It is, therefore, the ob ect of the lnvention to provide a control system which shall be simple and mexpensive in construction, and

reliable in operation. 7

Another ob ect of the invention. is to provide for controlling the excitation of a syn-c ehronous motor to increase its maximum or pull-out torque to meet peak load requirements. i

A more specific object of the invention is to provide for automatically increasing the ex.- citation of a synchronous mot-or when a peak load occurs and for decreasing the excitation when the peak load ceases to exist.

iUIOtllel ob ect of the inventlon is to provide for-automatically decreasing the resistance of'a synchronous motor lield circuit when the motor is subjected to a load inexcess of its over-load capacity, and for restoring the field circuit resistance to its proper value after the peak load has ceased to exist.

Other objects ofth-e invention will become eyident from the following description, taken in conjunction with the accompanying drawing, in which, 7 7' t Figure l is a diagrammatic view of a controlsystem" and apparatus connected in accordance with the invention, and, I

i 2 is a diagrammatic viewot' a modified control system suitable for motors which a direct connected to the driven machines Referring now to Figure 1 of the drawing, 10 designates generally a motor generator set comprising a synchronous motorll, connect ed bymeansof a shaft 12 to direct-current generator 13. In this instance, the synchronous motor 11 isprovided with a field winding 14: which may be energized from any constant potential source of direct-current energy. In this instance the field winding 14: is shown connected to the positive and negative conductors15 and 16 ofa power line. i

The direct-current generator 13 is also provided with a field winding 17 and its energization may be controlled by a variable resistor 18. As shown, the field and the resistor 18' are connected in series' In this particular instance, the generator 13 is connected in series relation with a D. C. motor 19 which is disposed to'drive a rolling mill indicated generally at 21.

y In order to simplify the drawing, only two of the rolls of a rolling mill are illustrated. As shown, the lower roll 22 is directly connected to the motor 19 by means of a shaft 24 in the usual manner. 7

It is to be understood that the upper roll 23 is adjustable with respect to the lower roll 22. The relative adjustment oi? the rolls may be effected in any manner well known in the art, and therefore the adjusting mechanism is not illustrated. 7

As shown, the motor 19 is provided with a field winding 25, which is disposed to be energized from the constant potential source comprising line conductors 15and 16.

In this particular embodiment of the invention, in order to momentarily increase the pull-out torque of the synchronous motor 11 when a peak load exists upon the driving motor 19, a D. C. power relay, shown generally at 26, is provided for controlling the excitation of the motor field winding 14. The power relay may be of any suitable type, and in this embodiment of the invention comprises a current coil 27 and voltage coil 28, the former being connected in the'clo-sed circuit of the generator 13 and motor 19 hereinbefore described, and the latter being connected in shunt relation to the motor 19.

In order to more clearly describe the operation of the power relay 26 in controlling the torqueot the synchronous motor 11, the operation of the system will be set forth in dctail.

In this instance the method of connecting the synchronous motor 11 to a suitable power source is of no importance, and starting means, being well known in the art, is not shown. However, it will be assumed that the stator leads 31, 82 and are connected to a suitable source of polyphase'powcr. The excitation of the synchronous motor 11 may be regulated by manipulation of the variable resistor 20, to cause the motor to operate at the desired power factor.

It will be noted that the field switch 34 ot the generator field circuit is open and, consequently, there is novoltage being developed by the generator 13. Upon the closure of the field switch 34, anenergizing circuit for the generator field is established and current flows from the positive conductor 15through conductor 35, field winding 17, variable resistor 18, switch 34, and conductor 36 to the:

negative line-conductor 16. V r

The voltage now developed bythe generator 13 may be controlled by the variable resistor 18. The motor 19 being connected in a closed circuit With the generator 18 is energized from the generator and the mill 21 is set in operation.

When an ingot is caused to pass between the rolls 22 and 23, a heavy load is imposed upon the drive motor 19, which is transmitted to thesynchronous motor 11. The load depends almost entirely upon the reducti'onthat is to be made during a particular pass through the mill, and, as it is desirable to make the first few passes as eiiective as possible, it will be readily understood that the synchronous motor 11, having very small overload capacity, may be overloaded and,

consequently, pull out of synchronism with the power source, which will result in a completeshut-down of the mill.

In order to prevent the stopping of the winding of the, synchronous motor 11 to increase its load capacity. I V I In the event that the power demand upon the generator 13 is greatly increased, the current coil 27 and the voltage coil 28'of the relay 26become energized and actuate the relay 26 to its closed position, short circuiting aportion of the field resistor 20. The eX- citing current of the synchronous motor 11 is instantly increased and flows through a circuit extending from the positive conductor 15, conductor 37, field winding 14, resistor 20, conductor 38, contact members. of the power relay 26, and. conductor 39 to the negative line conductor 16.

It will be readily understood that this increase ofexciting current may be regulated so to overexcite the synchronous motor 11 to any degree necessary to'obtain the-desired amount of maximum or pull-out torque.

.A thepeak load exists only momentarily, the increased exciting current likewise will exist only momentarily and nodamage to the field winding will result, even though the current carrying capacity of'the field has been greatly exceeded.

Reference may now be had to the modificationshown in Fig. 2, in which like reference numerals are employed to designate similar .parts. In this mstance, tlie synchronous motor 11 connected directly to the rolling mill i.

21 through the shaft 12. V

The same load conditions exist. in this instance as hereinbefore set-forth for the system shown in Fig. 1, and in order to increase the maximum orpu-ll-out torque of the syn chronousmotor 11, in response to the peak load. conditionswhich may exist, an alternating current power'relay-,;designated generally at. 41, isntilized.

The; relay all maybe of any suitable. type tact fingers 54 when the disc5l is rotated. In a synchronous motor and i adirect curre nt l former only in the manner in which the field of the synchronous motor, and means includand as shown. comprises the usual current adequatefo'r the'extremely high pe'ak load coils 42 and and voltage coil ll, the former conditions which may arise from time to time. being disposed to be energized by a current Since, certain changes maybe mad ein the transforn'ier 1:53 which is'connected in one of above described system and differentembodithe energy supply lines of the motor 12. The mentsof the invention may bema'dewithout 79 voltage coil isconnected in cir uit with the departing-from the scopethereof, it-isintendsecondary windings of a plurality of volted that all thematter contained in: the above 'age'trz'msformers 4i") and 4:7. A pair of redescription or shown in"the accompanying a'ctance coils-e8 and 49 are shown connected drawings, shall beinterpreted "as illustrative in the {relay circuit in 'the usual manner; *andm'ot'ina limited sense 1 flherelay all is also provided with a rotat- I claim as my invention: 'ingdisc 51, supported by a vertical shaft 52 The combination with fadirect'-current which carries'the movable contact member motor, a motor-generatorsetfor'controlling which 'isdisposed to engage the fixed con the direct-current-motor, said set comprising accordancewith the usual construction of "a generator, the direct-current generator and relay of this type, a coil spring 55 is prodirect current motor being connected'in a 1 vided which opposes the i clockwise rotationclosed circuit, means for excitin'g the generaof the disc 51 and maintains the movable tor and thetwo motors,{means for varying contact member 53 in a'disengaged position the excitation of the generator to vary the until the current and voltage coils become speed of the direct-current motor,the excitaenergized' to the desired degree. 1 tion means for the synchronous motor includ- It will be observed that this particular eming means-for varying the excitation in acbodiment of the invention differs from the cordance-with the normal load conditions "circuit oft-hesynchronous motor is 'cOn- 'ing a relay switch responsive to peak load trolled, the control means in the former beconditions of the direct-current motor for ining respoi'isive to the power demanded by the -creasing in a one-step operation, the excitadirect current driving motor, whereas in this tion ofthesynchronousmotorbeyondthevalue case, the A. G. power demanded by the synof excitation produced by the maximum con chronous motor is utilize'dto accomplish the tiiiuousfield-current for normal load'c'ondi same function. t'ionsduring theperiods of'said peak loads, The terniinals'of the field winding of the and reducing the excitation of said synchro synchronous motor ll are illustrated by the nous motor to its former'value in accordance "slip rings-55' and 56 which are shown mountwith normal load conditions during the reed uponthe shaft 12' The field circuit commainder of the load cycle. prises the variable resistor 20, similar to that 2. In a motor control system, in combinadescribedv hereinbeforc in connection with ,tion, a direct-current motor, a direct-"current Fig. 1.. generator connected in-a closed circuit with 3) As shown, a relay 58, having contact 1Y1Gl1'1' "the motor, a synchronous motor for driving; 3 5

bers 39 and an actuating coil 61is disposechthe direct currentgenerator, means forcxcitto short circuit a portion of the resistor 20. in'g'the' synchronous motor and the two di- Upon' certain undetermined peak load derect current machines, the excitation means mands on the synchronous motor 11, the pow-for the'synchronous motor? including means orrelay 4:1isenergized'sufficiently to cause for varying the degreeofexcitatioh for the '51.)

its operation, andthe'refore, move'the mov- Tnorma'lly rated: load conditions of-the" synable'contact member into engagemei'it chronous motor, and switching means for "with the fixed contact members 54' which quickly-increasin nin abrupt steps, the degree establishes an operating circuit for the relay of excitation of t ie'synchronous motor to in- 50 58-.which may be traced from the positive creaseitstorqueQsaid meansbeingresponsive 113' 20 is short circuited and the exciting current "the direct-current motor, said set comprising conductor 15,"thr'ough conductor 62, relay to predetermined peak load currents of the contacts 54, condu'ctor'63. C011 61, to the negageneratgn .i c

tive line conductor 16. Upon the closure of l 3; The combination with a direct-current therelay 58, a portion of the field reslstor motor,a imotor-generat or -set for-controlling for the synchronous motor 11 is instantly iIl-v a synchronous motor and a direct-currentv creased. a a "generator, the directs-current generator and It will be noted that by means of the above direct current motor being connected in l a described arrangement, that for operating 'closedcircuit, means for exciting the generalize a synchronous motor which is exactlyfor 'controlling the excitin'gfcurrent of the suited-to the normal load impressed upon it 'fieldwinding, and a relay-disposed to shortby the mill and in addition, provide forin circuit a portion. of s'aidresistor toi'nst antly creasing the maximum pull-out torqueof the increasethe exciting current ofth'eisynchromotor to such a degree that it will also be "nous motor to avalue above thenormalcapacits many types of steel mills it is possible toutitor and the two motors, a variablere'sistor 13:5

ity of the field winding, said relay being operable in response to a predetermined peak load ofthe direct-currentmotor.

4. The combination with a direct-current motor, a n'iotor-generator set for energizing the motor, said motor-generator set comprising a direct-current generator and a synchronous driving motor, thedirect-current generator being connected in a series, circuit with the direct-current. motor, a field winding for the synchronous motor, an exciting circuit for energizing said field winding, a variable resistor connected in the exciting circuit for controlling the current, a relay disposed to short circuit a portion of the resistor when actuated to the closed position, a relay actuating coil responsive to the generator voltage, a secondirelay actuating coil responsive to the direct-current flowing in therseries circuit, said actuating coils being disposed for the cumulative action in the operation of the relay.

5; In a direct-current motor load application in which theload is of an intermittent means for regulating the value of exciting current within the constant current carrying capacity of the field, and means responsive only to the brief-peak loadconditions of the direct-current generator for increasing the value of the synchronous motor exciting current beyond the constant current carrying capacity of the field, to increase the maximum value of torque developed 'by themotor at the instant the peak-load condition exists, and for reducing the exciting current to the formerconstant value after the peak-load has passed.

6. In a powerv system, in combination, a'

synchronous motor provided with field'and armature windings cooperative-to develop a predeternnned torque, a direct-current genorator supplying a varying load, said generator being driven by the synchronous motor, and means responsive to a preselected loadcurrent and voltage of the generator when the motor is operating near full -ca-- pacity, toincrease instantly the excitation of the: field windings, to temporarily increase thetorque that may :beidelive-red by themotor-to a value in excess cit-said predeterm-ined torque to meet peak load operating conditions.

7. In a power system for rolling mills, in combination, a synchronous motor rovided with a field winding, means for e ecting a transfer of power from the motor to the rolling mill, means for controlling the excitation of the motor field winding, said means comprising a resistor and a relay disposed to short circuit a portion of said resistor, said relay being responsive to the load imposed upon the motor when operating near its rated capacity, to increase the excitation of the field windings and thereby increase the maximum torque that may be developed by the motor.

8. In a power system for rolling mills, in combination, a synchronous motor rovided with a field winding, means for efFecting a transfer of power from the motor to the rolling mill, an energizing circuit for the field winding, a variable resistor connected in the energizing circuit for varying the field excitation to change theoperating characteristics of the motor, a relay operable to shunt a preselected portion of the resistor, said relay being disposed to respond only upon the occurrence of a preselected load determined by the pull-out torque of the motor, to suddenly over excite the motor field during the periods in which unusual peak load conditions exist, thereby to raise the value of the normal pull-out torque of the motor.

9. The combination with a direct-current motor, a motor-generator set for operating said motor, said set including a synchronous motor and a direct-current generator, and a relay, responsive to a predetermined voltage and load-current of said direct-current genorator, for increasing the exciting current of said synchronous motor.

10. In a power system in which the load is of an intermittent character having extreme peaks for brief periods of time, the combination of a direct-current motor, a motorgenerator set for supplying power to the direct-current motor, said motor-generator set comprising a synchronous motor and a direct-current generator, and a relay, responsive to a predetermined voltage of the generator at peakloadconditions, for quickly increasing the synchronous-motor exciting current.

In testimony whereof, I have hereunto subscribed my name this 18th day of November, 1927.

OLLIE NEEDHAM. 

